JPH01148809A - Novel polyester fibrous filler - Google Patents

Abstract

PURPOSE: To obtain a new polyester fiberfill having the specific number of continuous voids along the longitudinal direction of a filament arranged in a specified arrangement. CONSTITUTION: This fiberfill has at least seven continuous voids 21, 22 having substantially circular cross sections and arranged in the length direction in a filament 23 having about 5 to about 20 de size per filament. One of the voids is substantially positioned at the center, and the remainder of the voids 21 has substantially same size, and is peripherally arranged around the axial void 22 substantially at the same distance from the axial void 22 and from the periphery of the filament 23. The voids 21 are preferably arranged substantially at the same interval from the neighboring void. Some advantages can be provided by making the size of the axial void 22 large.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel polyester fiberfill containing a plurality of continuous voids along the length of the filament, a method for its manufacture and its use, and a method for producing the novel fiber. The present invention relates to an article filled with a filler material.

Polyester fiber filling material (sometimes polyester fiber filling material)
Decorative materials (also called furniture+g ma) include pillows, cushions and other bedding materials.
terial) and apparel.
1) have become well accepted as inexpensive filling and/or insulating materials and are commercially produced and used in large quantities. Initially, like other polyester fibers, the fibers were manufactured without voids (s), which was cheap to manufacture.
olicl) Fibers of circular cross section were used. This void-free circular polyester fill material is still in commercial use. However, about 20 years ago, for example, U.S. Patent No. 3,772 by Tolliver
, No. 137, and Glanzstotzf.
Hollow polyester filled materials have been suggested and used, such as that disclosed in British Patent No. 1,168,759 by M.T. The trivere exhibited a single hollow core or a central continuous longitudinal void. Although the preferred shape of the void is non-circular in cross-section, voids of more or less circular cross-section are also disclosed, and hollow polyester fiber-filled materials having a single central void of circular cross-section and of non-circular cross-section are used to fill the void. It is manufactured and used in large quantities because of its superior lightness (less density) in contrast to non-fiber-filled materials, and because of its improvement in insulation properties, as well as for other aesthetic reasons. Ta. More recently, E.P.A.
2 B7,884, the cross-section of the filament is characterized by four flat sides, characterized by four equally sized, equally spaced non-circular voids surrounding a void-free axial core. a serrated pleat structure to provide a high degree of bulk and bulk retention, and a lubricant (
A modified hollow polyester fiber-filled material is provided that has superior flexibility, more similar to the feel of natural down, in combination with a slickeniB agent.

However, it is surprising that the improvements that have become available in the last few years over the various actual configurations that have been suggested and used commercially for polyester fiber-filled materials with continuous longitudinal voids are Nevertheless, the new and improved polyester fiber-filled materials described in this invention offer advantages in contrast to any of the individual prior configurations considered individually, as will become clear below.

According to the invention, the filament t has at least seven continuous voids of substantially circular cross-section along its length, one of the voids being substantially centrally located, and the remaining voids mutually from about 5 to about 20 denier per filament, and located around the central void at substantially equal intervals from each other to the central void and from the perimeter of the filament. , a polyester fiber-filled material of substantially circular peripheral cross section is obtained. According to one embodiment, all voids are preferably of substantially the same size and are substantially equidistant from adjacent voids, so that in number, as specifically described and discussed below, There are exactly seven spaces, and a hexagonal packing arrangement is formed by the central void and six peripheral voids occupying the vertices of the hexagon.

However, by making the cross-sectional area of the central void slightly larger than that of the outer peripheral void, and arranging the outer peripheral voids at equal intervals from each other and also from the periphery of the central void, the benefits of a large central void can be obtained. There are also plans to do so. According to this embodiment, the peripheral cavities are preferably arranged symmetrically and are arranged in an even number, in particular eight, so that together with the central cavity they form a total of nine cavities.

The preferred total void content is at most about 8 to 25% (average area % measured across the cross section of the polyester filament).

As is known in the art and discussed later, the provision of pleats in polyester fiber-filled materials is extremely important for obtaining loft, i.e., large loft, and for its sustainability, and the frequency of pleats is preferably about 4 to about 12 per inch, or about 1.5 to about 5 per lem.

The fiber-filled material is preferably made slippery using a persistent lubricant.

According to the invention, novel polyester fibrous filling materials of this kind and surface-carrying filaments as described below, as well as single fillings of novel polyester fibrous filling materials of this type and other filling materials, are provided. Also provided are methods of making filled decorative and apparel items filled with this type of novel polyester fiber filled material, including filled mixtures with polyester fibers.

The fundamental element of the invention is the number and arrangement of continuous voids along the length of the plurality of circular filaments, which are believed to contribute to improvements over previous polyester fiber-filled materials that have been suggested and used. In retrospect, it can be assumed that at least some of the advantages of the present case can be explained by analogy and comparison with prior art configurations/sections, but this combination of factors is It is considered new.

The circular periphery is considered to be important. It is believed that it is important that the position of the voids is central, i.e. in the axial direction. It differs from the Tolliver configuration in that the polyester fiber-filled material of the present invention foresees multiple substantially parallel voids, whereas it only provides one void. In contrast, E P A 267.684 provides a plurality of substantially parallel voids (four in number) from which a polyester fiber-filled material of Toliver with only a single axially located void can be used. It is relatively soft and has brought out some improvement. EPA 267.684 polyester fiber-filled materials are unique in several respects. That is, it has a substantially quadrilateral peripheral shape, with a void-free axial core and only four continuous cores that are themselves non-circular and only have circular corners or lobes of the quadrilateral. It has parallel voids. As noted below, the polyester fiber-filled materials of the present invention also enable improvements in configurations that were more difficult to achieve with this prior art polyester fiber-filled materials, and perhaps even considered impractical. do.

Although the invention is not limited by any valid theory or by any speculative rational theory, it encompasses many factors and the reasons for the improvement are still incompletely understood. From the point of view, the plurality of voids including one central void in the configuration of the present invention provides better crush resistance in the sense that it provides higher stiffness with the same amount of voids.
sistance).

Furthermore, its pleat structure after shirring makes it more serrated or sharp-edged than would be obtained from the shirring of prior art polyester fiber-filled materials with similar void content. In contrast, a more circular corner is obtained, which (in combination with a circular peripheral cross section)
It can also be assumed that better frictional properties and greater durability in use could be expected. This is considered to provide an optimal symmetrical structure between this point and an optimal strength-double-weight (in the sense of lightness) relationship, so that the exact seven points shown in Figure 1 are For configurations with voids of the same size and equally spaced from adjacent voids, in other words, this may be especially true in hexagonal packing arrangements, but for some applications the size of the central void (in relation to the peripheral voids) may be ) would be more preferable to take advantage of the large central void associated with the multi-void structure suggested by Tolliver; in this regard, a symmetrical arrangement is believed to offer an advantage. In other words, a large central void 22 in a filament 23 with a substantially circular peripheral cross-section, as shown for example in FIG.
and eight equally spaced outer circumferential voids 21 that surround it and are equally spaced from the central void 11J* 22, for a total of nine substantially parallel voids may produce certain advantages. It is understood from this that other arrangements of voids surrounding a central void are possible, but will generally be less symmetrical than the hexagonal packed arrangement.

In principle, the technique of melt spinning hollow filaments from polyester and other synthetic polymers is long known and disclosed in the art. Boringe at -(H
, Bohringer) and Bolland (F., Bol.
LAND) is ``Development and Evaluation of hollow cored and profiled synthetic fibers without a hollow core.''
tion of Profiled 5ynthet
ic Fibers llll1th and
A paper entitled “Without HollowCore” (Fiber Research and Textile Technology (Faserfors)
Chung und Textilteehnik)
9.10 (October 1985, pages 405-418), in which he mentions several other publications. Although this publication is primarily directed to the provision of nylon filaments for use, for example, in the production of textile fabrics by knitting, as opposed to polyester fiber-filled materials used as filler materials, as far as the production of hollow filaments is concerned. Similar basic considerations apply. However, although some porous filaments are shown along with the spinneret design for obtaining porous filaments of this kind, this publication (in common with several others) is essentially It does not disclose any method of making the composition of the present invention with a central void in a circular filament and having a total of at least seven voids6, for example due to the thinness of the filament and voids, and the known post-orifice
Because of the phenomenon of e-bulging and the difficulty known as "kneeing," achieving this task requires considerable difficulty and extensive experimentation, and it is unlikely that this task was actually achieved. It is doubtful by some that this can be done.

However, as will be described later, this problem is solved by the fact that the six orifices 11 are as shown in FIG.
) and extrude the polymer through each orifice;
This is accomplished using a spinneret orifice design that is then fused to form a circular filament with seven equally spaced voids of substantially the same size as shown in FIG. In retrospect, this design follows general principles already conceptually understood in the industry, but as noted above,
It took considerable effort and experimentation to achieve circular porous polyester filaments with a central void as described in the present invention.

In addition to the formation of polyesters with the special configuration described in this invention, the production of filaments, including the manufacture of polymers, and the processing of filaments, their conversion into stable fibers, and the processing of fiber-filled materials and articles, such as pillows and Manufacture of other filled articles such as cushions;
or as a filling material for the formation of quilts, including quilted products such as garments, according to known procedures such as those described in the prior art referred to herein or elsewhere. It can be implemented.

As explained above, polyethylene terephthalate is generally preferred as the polyester polymer, given its commercial availability and cost, and the relative viscosity, in combination with processing conditions, is the desired Select appropriately to obtain the following configuration. For example, by Broaddus et al., February 11, 1987.
Co-pending application serial number 014,2 filed on
As described in No. 48, carbon chain branching agents (chain
-braneher) may also be used.

As mentioned above, see, for example, Hoffman U.S. Pat. No. 3,271,189, Meacl.
) et al., U.S. Patent Box 3,454,422, Ryan (
U.S. Patent Box 3,488,217 to Ryan and U.S. Patent Box 4,146,6 to Salamon et al.
No. 74 and Takemoto O
It has been known for a long time to ``impart slipperiness'' on polyester fiber-filled materials through the use of polysiloxane lubricants, as suggested in Japanese Published Patent Application No. 58-214.585 (1983) of Il & Fat Co, Ltd. Yes, and has been practiced commercially. Polysiloxanes and/or other lubricants are used to improve the aesthetics of polyester fiber-filled materials, and the use of such lubricants is preferred for certain purposes described in this invention. Co-pending Application Serial No. 921.64 filed October 21, 1986 by Mareus.
Non-silicone lubricants, such as those described in No. 6, have also proven advantageous for certain purposes. For many purposes, the lubricant is preferably "cured" onto the filament, such as by heating, to improve its persistence.

Reference is made in this regard in the following examples which further illustrate the invention.

Relative viscosity 20.4 (1 containing 100 ppm sulfuric acid)
80 in hexafluoroisopropanol of 01
Polyethylene terephthalate (measured at 25°C for polymer B) at a polymer temperature of 291-297°C, using the orifice shown in FIG.
With a distribution volume of 306 bonds/hour (0,139 kg/hour),
900 per minute through a spindle with 288 capillaries
yards (823 meters per minute) into filaments. This filament is twisted into a rope (914,
000 @ relaxed drawn denier
denier)). This flow 1 is drawn using the usual method with a draw ratio of 3°46
A hot wet spray extension zone kept at 0°C.

Stretch in a wet 5play draw zone). This elongated filament is passed through a regular cantilever-type stuffer box crisscrosser.
per) (dimensions 3.5 inches, 8.9 c+m) and relax the gathered rope in an oven at 180°C. A slickening finish containing a polyaminosiloxane is applied to the filament at about 0.32% by weight on the filament.
(solid silicone) and then approximately 0.07% by weight
Typical antistatic topcoat finish (antistatic)
a overlay finish). The fibers are cut to lengths of 3.0 inches (75+ua) using conventional techniques. This fiber has an average total void content of approximately IZ, 3% and 1
It is found to have a denier of about 9 per filament. The fiber has seven parallel, substantially equal-sized, continuous voids, six of which are equidistantly spaced around a seventh void forming the center of the fiber, as shown in FIG. It has a cross section of The periphery of the fibers is circular and smooth.

For comparison purposes, a similar denier sample (C) prepared as above in 1 but with four parallel continuous voids and a void-free axis with an average total void content of 17.7%. is gathered to approximately the same fold frequency and loft (at 0.2 psi) as a 7-hole fiber.

Various properties of the 7-hole sample (1) and the 4-hole comparative sample (C) were measured and listed in the table. It is noted that the F-F friction (coefficient of fiber-to-fiber friction) is lower (.0,001 psi) and the loft is slightly better, both of which are advantageous and surprising.

Both the 7-hole fiber-filled material described in the present invention and the 4-hole comparative example were made from a 20 ounce roll fill pillow.
j batting pillow))0
Although of similar height as shown in the table, the 7-hole fiber pillow feels substantially softer and more desirable both when new and after being stepped on in the laboratory. The 7-hole fibers appear to recover more slowly from compression. This is highly desirable.

F-F Pillow height (inch) l 7-hole 4.8 8.25
0.43 0.20B 9.15 8.0
Fu C4-hole 4.5 5.98 G, 45 0
．． 219 9.09 8.22 The main features and aspects of the present invention are as follows.

1. At least seven continuous voids of substantially circular cross section along the length of the filament, one of the voids being substantially centrally located and the remaining voids being substantially identical to each other; a substantially circular shape of about 5 to about 20 denier per filament, of size and located around the central void at substantially equal intervals from each other and from the periphery of the filament; Polyester fiber filled material with peripheral cross section.

2. The polyester fiber filling according to item 1 above, characterized in that there are seven voids, all of which are of substantially the same size and are arranged at substantially equal intervals from adjacent voids. material.

3. The polyester fiber-filled material according to item 2 of item 2E, characterized in that the fiber-filled material has slip properties using a persistent lubricant. 4. The total void content is about 8 to about 25%. The polyester fiber-filled material according to any one of the above items 1 to 3, characterized in that:

The polyester fiber-filled material according to any one of items 1 to 3 above, wherein the fiber-filled material is lathered into the fiber-filled material at a frequency of about 4 to about 12 fibers/inch.

6. having at least seven continuous voids of substantially circular cross-section along the length of the filament, one of the voids being substantially centrally located and the remaining voids being substantially identical to each other; by melt-spinning the polyester into filaments of substantially circular peripheral cross-section of size and located substantially equidistantly around and from the central cavity. An improved method for producing polyester fiber-filled materials characterized by improvements.

7. The polyethylene terephthalate has at least seven continuous voids of substantially circular cross section along the length of the filament, one of the voids being located substantially in the center, and the remaining voids being substantially mutually adjacent to each other. is the same size as, and
melt spinning into filaments having substantially circular peripheral cross-sections located at substantially equal intervals around a central void, and drawing the filaments from the central void; The production of polyester fiber-filled materials with slip properties, which consists of the steps of processing the filaments into tows, adding a lubricant, gathering, relaxing, and converting the filaments into stable fibers. Method.

8. The above filament is □ in the length direction of the filament.
seven voids of substantially circular cross section along the length, one of the voids being substantially centrally located, and the remaining voids being substantially the same size and substantially equal to each other. 8. A method according to paragraph 6 or 7 above, characterized in that they are located at intervals around the central cavity and are substantially equally spaced from the central cavity.

9. A padded cotton pad consisting essentially of the polyester fiber-filled material described in any one of items 1 to 3 above.

10. A filled ornament or clothing item filled with the polyester fiber filling material according to any one of items 1 to 3 above.

[Brief explanation of the drawing]

FIG. 1 is a micrograph of a cross-section of a typical polyester fiber-filled material according to one embodiment of the present invention. FIG. 2 is an enlarged view of a spinneret orifice suitable for melt spinning filaments of polyester fiber-filled material as shown in FIG. FIG. 3 is a representative example of a cross section of another embodiment of the present invention. Patent Applicant E.I. Dupont de Nimore” 1st page
Mi F! 0.1 ← Mortar J□p

Claims (1)

[Claims] 1. The filament has at least seven continuous voids of substantially circular cross section along its length, one of the voids being located substantially in the center, and the remaining voids being mutually adjacent. from about 5 to about 20 denier per filament, and located around the central void at substantially equal intervals from each other and from the periphery of the filament. , a polyester fiber-filled material with a substantially circular peripheral cross section. 2. At least seven continuous voids of substantially circular cross section along the length of the filament, one of the voids being substantially centrally located and the remaining voids being substantially identical to each other; by melt-spinning the polyester into filaments of substantially circular peripheral cross-section of size and located substantially equidistantly around and from the central cavity. An improved method for producing polyester fiber-filled materials characterized by improvements. 3. A padded cotton pad consisting essentially of the polyester fiber filling material according to claim 1. 4. A filled ornament or clothing item filled with the polyester fiber filling material according to claim 1.